GE Oil & Gas 28000 Series Masoneilan* VariPak* Adjustable-Cv Control Valves Instruction Manual
THESE INSTRUCTIONS PROVIDE THE CUSTOMER/OPERATOR WITH IMPORTANT PROJECTSPECIFIC REFERENCE INFORMATION IN ADDITION TO THE CUSTOMER/OPERATOR’S NORMAL OPERATION AND MAINTENANCE PROCEDURES. SINCE OPERATION AND MAINTENANCE PHILOSOPHIES VARY, GE (GENERAL ELECTRIC COMPANY AND ITS SUBSIDIARIES AND AFFILIATES) DOES NOT ATTEMPT TO DICTATE SPECIFIC PROCEDURES, BUT TO PROVIDE BASIC LIMITATIONS AND REQUIREMENTS CREATED BY THE TYPE OF EQUIPMENT PROVIDED.
Contents 1. General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 1.1 Spare Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 1.2 After Sales Department . . . . . . . . . . . . . . . . . . . . . . . . . . .
1. General These installation, operation, and maintenance instructions apply to Masoneilan VariPak* 28000 series control valves. They also include a parts reference list with recommended spare parts (see page 21). IMPORTANT REMARKS Before installing, operating, or performing maintenance on this equipment, you should read these instructions carefully and make sure you have understood them. Work on this equipment should only be carried out by qualified personnel.
2. Operation The Masoneilan VariPak microflow control valve features a very wide range of rated flow coefficients (Cv), from 0.004 to 3.8. 2.2 FLOW COEFFICIENT OF VARIPAK 28001 SINGLE-LEVER AND 28002 ADJUSTABLE-Cv VALVES Two types of actuators are available: - The VariPak 28001 with a single lever, designed for just one rated Cv. This version is used when enough is known about the operating conditions when sizing the valve.
Plug and seat ring No. 9 Plug and seat ring No. 8 Plug and seat ring No. 7 Plug and seat ring No. 6 Plug and seat ring No. 5 Plug and seat ring No. 4 Plug and seat ring No. 3 Plug and seat ring No. 2 Plug and seat ring No. 1 Plug and seat ring No. 0 VariPak 28001 Cv 0.004 Cv 0.010 Cv 0.010 Cv 0.050 Cv 0.10 Cv 0.25 Cv 0.60 Cv 0.2 Cv 2.3 Cv 3.8 VariPak 28002 Cv 0.004 to 0.0016 Cv 0.010 to 0.004 Cv 0.010 to 0.004 Cv 0.050 to 0.010 Cv 0.10 to 0.04 Cv 0.25 to 0.10 Cv 0.60 to 0.
Follow the procedure described in the "Disassembly/ Reassembly" section of the "Maintenance" chapter on pages 14 to 18. - Loosen adjustment knob (24) and slide it along the lever to the required value. Tighten the adjustment knob again firmly. - Also change the serial plate (135) or correct the information on the existing plate. Note: - This operation entails moving lever No.
When the handwheel (120) is turned clockwise, the stop (122) moves up the threaded rod, compressing the spring (134) and raising lever No. 2 (22) (VariPak 28002) or (113) (VariPak 28001). This closes the valve if the valve is equipped with a direct-action actuator (Air-to-Close) and opens the valve if it is equipped with a reverseaction actuator (Air-to- Open).
Note: Ensure that the clevis is correctly positioned before fitting the lever No. 1 on the bracket (108). N. Put the valve back into service. J. R eset adjustment knob (24) to the minimum Cv position. - When replacing an Air-to-Close actuator with an Air-toOpen actuator, do not forget to neutralize the limit stop by screwing it down at the bottom of the piston. K. C ouple plug stem clevis (104a) to lever No. 1 following the normal reassembly procedure (step L.
3. Installation 3.1 Preliminary Steps A. B efore installing the valve in the line, remove all traces of foreign material from the piping such as welding chips, scale, oil, grease, etc. B. Note down all the data given on the serial plate. C. For valve inspection without interrupting process operation, a hand-operated stop valve will be required on either side of the VariPak, together with a hand-operated throttling valve mounted on a bypass line. 3.
Insulation: If the valve is to be insulated, ensure that the insulation does not exceed the shaded area shown in figure 10 below. Figure 12 - Connections with 7700E positioner Figure 10 - Insulation limit for a VariPak valve 3.3 Pneumatic and Electrical Circuit (Figures 3, 11 and 12) - On-off valve: connect the air supply line directly to the 1/8" NPT threaded connection in diaphragm cover (137).
4. Calibration VariPak valves are factory-calibrated according to the components specified in the customer order. If for any reason this calibration has been disturbed (e.g. after changing from direct to reverse valve action, or replacing the plug and seat ring), all or some of the adjustments below must be carried out in the following order: - Piston rod clevis (104b) adjustment. - Plug stem adjustment. - Limit stop adjustment. - Cv adjustment. - Positioner start-up pressure adjustment. 4.
B. F it lever (113) with spring clamp (115) positioning hole facing upwards, fit pin (105) into hole A, then fit pin (18) into clevis (104a). Note: All pins should be greased slightly before fitting. C. Press the lever on the actuator side to check for plug/ seat ring leaks at ΔP 3.5 barg (50 psig). If the valve is equipped with a handwheel, lever (113) should not touch lever arm stop (122). If the valve leaks, release the pressure at the inlet and remove pin (18) of clevis (104a), then loosen nut (103).
4.4 VARIPAK 28002 Cv ADJUSTMENT This adjustment is carried out by moving adjustment knob (24) along adjustment plate (25) fastened to the top of lever No. 1 (21). See section “Adjusting the Cv of a Varipak 28002 valve for each plug and seat ring combination”, page 7. 4.5 POSITIONER START-UP PRESSURE ADJUSTMENT (Figures 7, 25, 26 and 27) A. C onnect the air supply and signal lines to the 7700P or 7700E (with electrical signal) positioner. B.
5.3 DISASSEMBLY (Figures 5, 24, 25, 26, 27, 28 and 29) remove balance spring (114) from the positioner. In some cases, it may be necessary to disassemble the VariPak valve, for example, to replace the plug/seat ring assembly (fitting new parts or changing the maximum Cv value) or to change the packing rings when the maximum Cv is less than 0.6. E. R emove the retainer clip (112b) from each of the two pins (184) and disengage the pins from lever No. 1 and clevis (104a). Note: If the maximum Cv ≥ 0.
- VariPak valves with Cv max. 3.8 do not have seatring gaskets (2). 5.4 REASSEMBLY (Figures 5, 15, 19, 20, 24, 25, 26, 27, 28 and 29) Before reassembly, thoroughly clean the inside of the valve body and parts, paying particular attention to gasket seating surfaces and contact surfaces. Make sure to use a new seat-ring gasket (2) and new packing (6) during reassembly. A.
Reassembly procedure for the VariPak 28002 adjustable-Cv valve (continued): H. Couple lever No. 2 (22) to the actuator bracket (108) using pin (18). Ensure that the hole in lever No. 2 where spring clamp (115) is fitted is located above and in line with balance spring (114). Figure 20 - Plug stem pre-adjustment for VariPak 28002 adjustable-Cv Reassembly procedure for the VariPak 28001 singlelever valve (continued): H.
spacer (5). The function of the safety pin and spacer is to prevent the plug from being pushed out if the actuator is accidentally removed while the valve is still pressurized. The internal parts of the valve cannot be removed unless the safety pin is removed first. Remove the two packing flange nuts (8b) and back off the two actuator bracket mounting nuts (8a) as far as possible. N. A dmit the signal and supply pressure and complete calibration. Refit cover (110) using the two screws (109).
B. L oosen the two cap screws (141a) and remove manifold block (144), spring (158), gasket (146) and its three O-rings, pilot valve assembly (155 to 157), shims (145), and O-ring (153). Caution: Handle the shims carefully (145). C. Loosen locknut (117) and take-up screw (116), unhook the spring clamp from lever (22) or (113). D. Unscrew cap screws (141b) from positioner block (147) and remove the positioner block from the actuator bracket.
5.8 CONVERTING A 7700P POSITIONER (PNEUMATIC) INTO A 7700E POSITIONER (ELECTROPNEUMATIC) C. If the parts mentioned above have been removed, proceed as follows: A kit comprising the manifold block (144) and the I/P module (20) is available from your local Masoneilan representative or the Spare Parts Department. Fit the O-ring (153), shims (145), pilot valve assembly (155 to 157), gasket (146) and the three O-rings, the spring (158) and manifold block (144) - I/P module (20).
Figure 24 - Cross-section of the VariPak 28002 adjustable-Cv actuator and the 7700P positioner PARTS LIST Ref. Δ ☐ 1 Ο 2 a b c 3 ☐ ☐ 3 4 5 Ο 6 7 8 8 9 10 11 12 13 13 18 20 21 22 23 24 25 26 27 28 29 30 Ο Ο Ο d e f a b a b c d a b Qty 1 1 1 1 1 1 1 1 1 1 1 2 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 4 1 1 1 Part Name 1/4" NPT pipe plug Seat-ring gasket Seat ring Cv max. 3.8 Seat ring Cv max. 2.
Figure 25 - C ross-section of the VariPak 28001 single-lever actuator and the 7700E positioner 181 180 Figure 26 - Partial cross-section of VariPak 28001 single-lever, air-to-open valve 22 | GE Oil & Gas
Masoneilan VariPak Adjustable Cv Control Valves Instruction Manual | 23
181 180 Figure 27 - Partial cross-section of VariPak 28002 adjustable-Cv, air-to-open valve Figure 29 - Coupling detail of levers No.
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